Toy figure with articulating joints

ABSTRACT

A toy figure having multiple articulating limbs connected to the torso by pivot joints that are molded in a vertical injection molding step that forms and pivotally interconnects, in situ, one member of the pivot joint to a second, pre-formed member of the pivot joint.

FIELD OF THE INVENTION

[0001] This is a continuation application of U.S. patent applicationSer. No. 09/499,380, filed Nov. 24, 1999, which in turn is acontinuation-in-part application of U.S. patent application Ser. No.09/088,385, filed Jun. 1, 1998, now U.S. Pat. No. 6,084,950. The presentinvention generally relates to jointed toy figures and more specificallyrelates to toy figures with an unusually large number of uniquearticulating parts which give the figures a particularly realistic lookand feel.

BACKGROUND OF THE INVENTION

[0002] Toy figures with articulating limbs are generally known. Toyfigures having a large number of articulating limbs are not widelyavailable because of expenses associated with manufacturing andassembling the completed toy figure. Additionally, as the toy figuresdecrease in size below about 10-12 inches in overall length, the costsof manufacture and assembly increase considerably because of difficultyin constructing and attaching small limbs with multiple movable joints.A further problem in providing relatively small toy figures withmultiple articulating parts concerns producing small joints that aredurable and have the close tolerances necessary to provide sufficientfriction between the moveable surfaces of the joints necessary forproper operation of the joints. Also, it has long been a goal to combinerealistically articulating limbs with adjacent body parts in a mannerwhich minimizes any undesirable gaps so that the outer surface of thearticulating figure has a relatively continuous, life-like appearance.

[0003] It would therefore be very desirable to provide a toy figure withmultiple articulating limbs having improved joint construction withincreased durability for manipulation through a variety of realisticposes. It would also be desirable to provide methods which reduce theamount of time and labor needed for assembling toy figures of varioussizes, including small sizes, having articulating limbs. It would alsobe very desirable to provide toy figures, especially toy figures with anoverall length less than about 10 inches, that provide improved jointoperation. Furthermore, it would be very desirable to enable themanufacture of toy figures with realistic articulating limb and torsoparts having outer surfaces free of screws or other visible fastenersand having reduced gaps between the connected parts.

SUMMARY OF THE INVENTION

[0004] The present invention provides toy figures having articulatinglimbs with a large number of joints. The toy figures of the presentinvention include one or more pivotally connected parts having a firstjoint member made of a first material, preferably a first thermoplasticmaterial, and a second joint member made of a second thermoplastic whichhas a melting point that is less than that of the first material. Thefirst and second joint members are advantageously pivotally connected toone another in an in situ injection molding method of the invention.Thus, in another of its aspects, the present invention includes a methodof connecting a first joint member and a second joint member in an insitu injection molding process, wherein the first joint member is formedof a first material and the second joint member is formed of a secondmaterial which is a thermoplastic material, wherein the first jointmember is inserted in a predetermined position into an injection mold,as an insert part, and the second thermoplastic composition is injectedto form the second joint member around the first joint member, pivotallyconnecting the two. In a presently preferred embodiment, the firstthermoplastic composition is an acrylonitrile butadiene styrene (ABS)and the second thermoplastic composition is a polyvinylchloride (PVC)composition having a melting point of about 160° C. and the differencein melting points is at least about 70° C.

[0005] In another of its aspects, the present invention includes amethod for making an articulating limb having first and second limbsegments connected by an elongate member. The elongate member is formedof a first material and the first and second leg segments are formedfrom a second material having a melting point lower than the meltingpoint of the first material. In this method, the elongate member isplaced into an injection mold having a cavity for forming the first limbsegment and a cavity for forming the second limb segment. The elongatemember is positioned in the injection mold such that one end of theelongate member is within the first cavity and the other end of theelongate member is within the second cavity. The second material is theninjected into the mold at a temperature equal to or higher than themelting point of the second material but lower than the first material'smelting point. In this manner, the first and second limb segments areformed around the elongate member, the first limb segment beingconnected to one end of the elongate member, and the second limb segmentbeing connected to the elongate member's other end.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006]FIG. 1 is a front elevation view, partially in cross-section,depicting a toy figure having features of the present invention;

[0007]FIG. 2 is an exploded perspective view of the toy figure of FIG. 1illustrating the head, torso and left limbs of the toy figure, it beingunderstood that the right limbs are corresponding mirror-images of theleft limbs;

[0008]FIG. 3 is an exploded perspective view of the component parts ofthe toy figure of FIG. 1 which comprise a left arm subassembly extendingfrom the shoulder to the elbow just prior to assembly and ultrasonicwelding in an ultrasonic welding device as depicted in this FIG.;

[0009]FIG. 4 is an exploded perspective view of the upper torso,head/head joint, left and right arm assemblies and the body joint of thetoy figure of FIG. 1 prior to assembly and ultrasonic welding;

[0010]FIG. 5 is an exploded view of the upper torso produced in theassembly step depicted in FIG. 4, the lower torso, and left and rightleg assemblies prior to assembly and ultrasonic welding to complete thetoy figure of FIG. 1;

[0011]FIG. 6 is a perspective view of a first joint member used as aninsert part in the in situ injection molding process, wherein the insertpart is pivotally connected to a second joint member to form thepivoting left shoulder of the toy figure of FIG. 1;

[0012]FIG. 7 is an elevation view of the insert part of FIG. 8 inconjunction with the second joint member, including a pivot pin, asformed in an injection mold, with part of the mold cut away for purposesof illustration;

[0013]FIG. 8 is a perspective view of the pivotally connected first andsecond joint members made by injection molding, as in FIG. 7, showing inphantom lines the position and connection of the insert part (firstjoint member) depicted in FIG. 6;

[0014]FIG. 9 is a perspective view of an insert part which provides theball member of a ball and socket joint of the invention whichcorresponds to the body joint of the toy figure of FIG. 1;

[0015]FIG. 10 is an elevation view of the insert part of FIG. 9 inconjunction with a socket member, as formed in an injection mold, withpart of the mold cut away for purposes of illustration;

[0016]FIG. 11 is a perspective view of the ball and socket joint made byinjection molding, as in FIG. 10, showing in phantom lines the positionand connection of the insert part (first joint member) depicted in FIG.9 to the body of the socket member (second joint member) of the ball andsocket joint;

[0017]FIG. 12 is a perspective view of an insert part used in thehand/wrist of the toy figure of FIG. 1;

[0018]FIG. 13 is an exploded perspective view of the finger members andpivot pin used (in combination with the insert part of FIG. 12) to forma left hand according to a method of the present invention;

[0019]FIG. 14 is a perspective view of the finger members of a left handof a figure of the present invention with the finger members pivotallymounted on a pivot pin prior to the injection molding step to completethe left hand;

[0020]FIG. 15 is a perspective view of a left hand of the toy figure ofthe FIG. 1 made by a molding method of the present invention;

[0021]FIG. 16 is an elevation view of the insert parts of FIGS. 12 and14 in conjunction with a left hand of the toy figure of the presentinvention, as formed in an injection mold, with part of the mold cutaway for purposes of illustration;

[0022]FIG. 17 is a front elevational view, partially exploded,illustrating the head, torso and left limbs of another toy figure havingfeatures of the present invention, it being understood that the rightlimbs are corresponding mirror-images of the left limbs;

[0023]FIG. 18 is a front elevational view, partially exploded, of thetoy figure of FIG. 17;

[0024]FIG. 19 is an elevation view, in partial cross-section, of theleft arm of the toy figure of FIG. 17 as formed in an injection mold;

[0025]FIG. 20 is a perspective view of the left arm of the toy figure ofFIG. 17, showing in phantom lines the position and connection of theelongate member and the connecting member;

[0026]FIG. 21 is a perspective view of the connecting member of the leftarm of the toy figure of FIG. 17;

[0027]FIG. 22 is a perspective view of the elongate member of the leftarm of the toy figure of FIG. 17;

[0028]FIG. 23 is an exploded perspective view, partially incross-section, of another embodiment of the elongate member of the leftarm in association with the first arm segment;

[0029]FIG. 24 is a perspective view of another embodiment of the leftarm, showing in phantom lines the position and connection of theelongate member of FIG. 23 and the connecting member;

[0030]FIG. 25 is a perspective view of the elongate member of the leftleg of the toy figure of FIG. 17;

[0031]FIG. 26 is an elevation view, in partial cross-section, of theleft leg of the toy figure of FIG. 17 as formed in an injection mold;

[0032]FIG. 27 is a perspective view of the left leg of the toy figure ofFIG. 17, showing in phantom lines the position and connection of theelongate member of FIG. 25;

[0033]FIG. 28 is a perspective view, partially exploded, of the left legand hip segment of the toy figure of FIG. 17;

[0034]FIG. 29 is an exploded perspective view, partially incross-section, of another embodiment of the elongate member of the leftleg in association with the first leg segment;

[0035]FIG. 30 is a perspective view of another embodiment of the leftleg, showing in phantom lines the position and connection of theelongate member of FIG. 29;

[0036]FIG. 31 is a perspective view of the lever arm of the head of thetoy figure of FIG. 17;

[0037]FIG. 32 is a perspective view of the head of the toy figure ofFIG. 17, showing in phantom lines the position and connection of thelever arm of FIG. 31;

[0038]FIG. 33 is an elevation view, in cross-section, of the head of thetoy figure of FIG. 17 as formed in an injection mold;

[0039]FIG. 34 is a front elevational view, in partial cross-section,depicting another embodiment of the torso mounting structure of a toyfigure of the present invention;

[0040]FIG. 35 is an elevation view, in partial cross-section, of theembodiment of the left arm of FIG. 24 as formed in an injection mold;

[0041]FIG. 36 is an elevation view, in partial cross-section, of theembodiment of the left leg of FIG. 30 as formed in an injection mold;

[0042]FIG. 37 is an exploded perspective view, partially incross-section, of another embodiment of the elongate member of the leftarm in association with the first arm segment;

[0043]FIG. 38 is a perspective view of another embodiment of the leftarm, showing in phantom lines the position and connection of theelongate member of FIG. 37 and the connecting member;

[0044]FIG. 39 is an elevation view, in partial cross-section, of theembodiment of the left arm of FIG. 38 as formed in an injection mold;

[0045]FIG. 40 is a perspective view of another embodiment of theelongate member of the left arm;

[0046]FIG. 41 is a perspective view of another embodiment of the leftarm, showing in phantom lines the position and connection of theelongate member of FIG. 40 and the connecting member;

[0047]FIG. 42 is an elevation view, in partial cross-section, of theembodiment of the left arm of FIG. 41 as formed in an injection mold;

[0048]FIG. 43 is a perspective view of another embodiment of theelongate member of the left leg;

[0049]FIG. 44 is a perspective view of another embodiment of the leftleg, showing in phantom lines the position and connection of theelongate member of FIG. 43;

[0050]FIG. 45 is an elevation view, in partial cross-section, of theembodiment of the left leg of FIG. 44 as formed in an injection mold;

[0051]FIG. 46 is an exploded perspective view, partially incross-section, of another embodiment of the elongate member of the leftleg in association with the first leg segment;

[0052]FIG. 47 is a perspective view of another embodiment of the leftleg, showing in phantom lines the position and connection of theelongate member of FIG. 46; and

[0053]FIG. 48 is an elevation view, in partial cross-section, of theembodiment of the left leg of FIG. 47 as formed in an injection mold.

DETAILED DESCRIPTION OF THE INVENTION

[0054] Reference is made to FIG. 1 of the drawings which depicts a toyfigure designated by reference numeral 10. Toy figure 10 includes atorso 12 and limbs including a left arm 14, a right arm 16, a left leg18, and a right leg 20, as well as a head 22.

[0055] In a preferred embodiment, left arm 14 and right arm 16, whichare shown in different orientations in FIG. 1, comprise a plurality ofarm segments designated by numerals 24, 42, 58, 66, 80 and 102. Thesearm segments are interconnected at joints 14 a, b, c, d, e and f and 16a, b, c, d, e and f, respectively, to provide articulating left andright arms 14 and 16. Since the two arms 14 and 16 and the two legs 18and 20, as well as the component parts thereof, are mirror-images ofeach other, we will describe the details of left arm and left leg 14 and18, it being understood that the corresponding right arm and right leg16 and 20 are comprised and assembled identically.

[0056] With reference to FIGS. 1 and 2, first arm segment 24 has agenerally spherical top portion 26 with a short trunk 26 a dependingtherefrom and integrally formed therewith to give the appearance of aleft shoulder and approximately the upper ⅓ of the upper arm. Sphericalbody 26 has an arcuate opening 27 into the interior of first arm segment24. A joint member 25 having a lever arm 28 is pivotally attached tofirst arm segment 24 at joint 14 a. Lever arm 28 terminates at one endin a disk 30 and at the other end in a ring 31 Ring 31 has a bore formounting joint member 25. Ring 31 of lever arm 28 extends througharcuate opening 27 and is pivotally mounted on pivot pin 33 formed inthe first arm segment as described below.

[0057] This mounting of joint member 25 inside trunk 12 permits firstarm segment 24 to pivot at joint 14 a through an arc A of approximately90°. Thus, when first arm segment 24 is mounted to trunk 12, asdescribed more fully below, arm segment 24 is capable of pivoting withinthe arm hole 36 of the trunk such that the gap between the outer surfaceof body 26 of the first arm segment and the circular edge 38 of arm hole36 is small at all positions of first arm segment 24 along arc A.

[0058] First arm member 24 further comprises a disk 32 spaced apart froma bottom surface of body 26 a by a short shaft 34, by way of which firstarm segment 24 is rotatingly connected to second arm segment 42. As bestseen in FIG. 2, second arm segment 42 has complementary second armsegment shells 42 a and 42 b which are attached by way of a cylindricalpin 50 in second arm segment shell 42 a having a bore 52 therein forreceiving assembly pin 54 extending from the inside surface of secondarm shell 42 b. When these second arm segment shells are assembled, disk32 of the first arm segment is seated in a corresponding circularinterior space 46 with shaft 34 extending through a bore in top wall 44of second arm segment 42, the bore being formed by complementarysemi-circular cut-outs 48 a and 48 b in top wall 44. With disk 32positioned in interior space 46 and resting against the interior surface44 a of top wall 44, second arm segment 42 is capable of rotating 360°about the axis of shaft 34 at joint 14 b with respect to first armsegment 24. Additionally, second arm shell 42 has an arcuate opening 56extending along the curved body surface of second arm segment 42adjacent pin 50 which permits movement at joint 14 c, as explainedbelow.

[0059] Left arm 14 further comprises a third arm segment 58 which actsas a double pivot member comprising. Third arm segment 58 has a plate 60with bores 62 and 64 extending transversely therethrough at the oppositeends of the plate. Third arm segment 58 is connected through bore 62 topin 50 in second arm segment 42 to provide joint 14 c, a pivot joint.

[0060] Left arm 14 further includes a fourth arm segment 66 which ispivotally connected to third arm segment 58 at joint 14 d. Fourth armsegment 66 comprises complementary fourth arm segment shells 66 a and 66b. Fourth arm segment shell 66 a is provided with a pivot pin 68 whichpasses through bore 64 to provide pivoting motion. Pin 68 has a bore 70therein to mate with complementary assembly pin 71 in fourth arm segmentshell 66 b. As will be appreciated from an inspection of FIGS. 1 and 2,fourth arm segment 66 is analogous in structure and function to secondarm segment 42, albeit shorter in overall length and inverted withrespect to the orientation of second arm segment 42. Thus, fourth armsegment 66 has a circular interior space 72 (analogous to circularinterior space 46) and a bottom wall 74 defining semi-circular cut outs74 a and 74 b defining a bore 76 in communication with interior space72.

[0061] Fourth aim segment 66 thus is connected to third arm segment 58by inserting pin 68 through bore 64 of the third arm segment 58 toprovide joint 14 d. Thus it will be appreciated that third arm segment58 provides a double pivot member which allows second arm segment 42 andfourth arm segment 66 to independently pivot with respect to third armsegment 58 at joints 14 c and 14 d, respectively.

[0062] When the second arm segment and fourth arm segment are pivotedtoward each other, each of the respective arm segments are capable ofpivoting through an arc of about 90° (represented by B and C) such thatthe second and fourth arm segments may be pivoted a total ofapproximately 180° with respect to one another with the third armsegment thus functioning as an elbow joint. Because the third aimsegment 58 uses a double pivot arrangement whereas a natural human elbowjoint has a single pivot point, the second and fourth arm segments arespaced apart from each other.

[0063] As best seen in FIG. 1, when left aim 14 is fully extendedlengthwise, third arm segment 58 abuts end wall 56 a of arcuate opening56 in the bottom of second arm segment 42 and end wall 78 a definingarcuate opening 78 of the fourth arm segment to provide a continuousouter arm surface. Third arm segment 58 is provided with wing-likeextensions 80 which extend outwardly and curve slightly downwardly fromthe outer edge 83 to fill in the gaps caused by the pivotal attachmentof second and fourth arm segments 42 and 66 at opposite ends of thirdarm segment 58, as needed to assure that articulating left arm 14 has afull range of motion about third arm member 58. The wing-like extensionsthus allow arm 14 to exhibit a relatively continuous outer arm surfacewhere second and fourth arm segments 42 and 66 are joined to third armsegment 58 without interfering with the pivoting arm segments.

[0064] Left arm 14 further comprises a fifth arm segment 80 which isrotatingly connected to fourth arm segment 66 at joint 14 e by lower armjoint member 82. Joint member 82 comprises a disk 84 and a plate 86spaced apart from each other by a short shaft 88. Fifth arm segment 80comprises complementary shells 80 a and 80 b having a pivot pin 90 witha bore 92 therein with complementary fifth arm segment shell 80 b havingan assembly pin 94 extending therefrom to fit within bore 92. Fifth armsegment 80 also has a circular interior space 96 and a top wall 98 witha bore 100 therethrough in communication with interior space 96. As willbe appreciated from an inspection of FIGS. 1 and 2, fifth arm segment 80and fourth arm segment 66 are essentially identical in structure andoperation but are of different respective dimensions. When fourth andfifth arm segments 66 and 88 are rotatingly connected at joint 14 e bylower arm joint member 82, fourth and fifth arm segments 66 and 80 aremated at their respective walls 74 and 98 with shaft 88 extendingthrough bores 76 and 100 and with disk 84 seated on the interior surfaceof wall 74 and plate 86 seated on the interior surface of wall 98. Thusfourth and fifth arm segments 66 and 80 are capable of rotating withrespect to one another 360° about shaft 88, with disk 84 rotating ininterior space 72.

[0065] Left hand 102, which is discussed in detail below, includes aring 104 with a central bore 106. Ring 104 is spaced apart from thebottom wall 108 of left hand 102 by shaft 110. Left hand 102 ispivotally connected at joint 14 f to fifth arm segment 80 by way of themounting of ring 104 on pivot pin 90, with shaft 110 extending throughan arcuate opening 91 in arm segment 80. Left hand 102 therefore pivotson pivot pin 90.

[0066] In another embodiment shown in FIGS. 17-22 and particularlysuitable for toy figures three inches or less in overall height, leftarm 14 comprises a first arm segment 500, a second arm segment 505, andan elongate member 510. As shown in FIGS. 17-21, first arm segment 500has a proximal end 515 and a distal end 520, second limb segment 505 hasa proximal end 525 and a distal end 530, and elongate member 510 (asshown in FIG. 22) has a first end 535 and a second end 540.

[0067] Proximal end 515 of first arm segment 500 is adapted to beconnected to upper torso 250 of the toy figure. In the preferredembodiment, connecting member 565 (shown in FIG. 21) connects proximalend 515 to upper torso 250. Connecting member 565 has a body-part end590 comprising a disk 575, and a limb end 595 comprising a ring 580defining an aperture 585. Proximal end 515 of first arm segment 500comprises an integrally formed interior pivot pin 600 (see FIG. 19) anddefines a slot 560. A pivotal connection between arm segment 500 andconnecting member 565 is formed with ring 580 extending through slot 560into the interior of arm segment 500 and pivot pin 600 extending throughaperture 585. Body-part end 590 of connecting member 656 is rotatablyconnected to upper torso 250 by seating disk 575 within a mountingstructure analogous to the mounting structure described in more detailbelow with respect to disk 30.

[0068] Distal end 520 of first arm segment 500 is connected to first end535 of elongate member 510. In the embodiments shown in FIGS. 17, 19,20, 22, 41, and 42, distal end 520 of first arm segment 500 is pivotallyconnected to first end 535 of elongate member 510, with first end 535comprising a ring 542 defining an aperture 545 and distal end 520comprising pivot pin 550 extending through aperture 545. (A perspectiveview of an embodiment of such an elongate member 510 is shown in FIG.40.) In the embodiments shown in FIGS. 23, 24, 25, 37, 38 and 39, distalend 520 of first arm segment 500 is rotatably connected to first end 535of elongate member 510, with first end 535 comprising disk 251 anddistal end 520 defining a circular interior space 560 capturing disk251.

[0069] Proximal end 525 of second arm segment 505 is connected to secondend 540 of elongate member 510. In the preferred embodiments, the secondarm segment's proximal end 525 is either pivotally (see FIGS. 19, 20,22, 23, 24 and 35) or rotatably (see FIGS. 37, 38, 39, 40, 41 and 42)connected to the elongate member using a pivot pin or a disk,respectively, in a manner analogous to that described above with respectto distal end 520.

[0070] In one embodiment, left leg 18 comprises a plurality of legsegments which are interconnected at a series of joints to provide thearticulating leg whose structure and movement correspond to arm 14described above. Thus, leg 18 comprises first, second, third, fourth andfifth leg segments 124, 142, 158, 166, and 180 which are analogous tothe left arm segments 24, 42, 58, 66 and 80, as well as to the right armsegments 24 r, 42 r, 58 r, 66 r and 80 r and right leg segments 124 r,142 r, 158 r, 166 r and 180 r.

[0071] With reference to FIGS. 1 and 2, first leg segment 124 has agenerally spherical top portion 126 with a short trunk 126 a dependingtherefrom and integrally formed therewith to give the appearance of aleft hip and approximately the upper ⅓ of the upper leg. Spherical body126 has an arcuate opening 127 into the interior of first leg segment124. A joint member 125 having a lever leg 128 is pivotally attached tofirst leg segment 124 at joint 18 a. Lever arm 128 terminates at one endin a disk 130 and at the other end in a ring 131. Ring 131 has a borefor mounting joint member 125. Ring 131 of lever leg 128 extends througharcuate opening 127 and is pivotally mounted on pivot pin 133 formed inthe first leg segment as described below.

[0072] This mounting of joint member 125 inside trunk 12 permits firstleg segment 124 to pivot at joint 18a through an arc D of approximately90°. Thus, when first leg segment 124 is mounted to trunk 12, asdescribed more fully below, leg segment 124 is capable of pivoting withrespect to trunk 12 such that the gap between the outer surface of body126 of the first leg segment and the circular edge 138 of leg hole 136is small at all positions of first leg segment 124 along arc D.

[0073] First leg member 124 further comprises a disk 132 spaced apartfrom a bottom surface of body 126 a by a short shaft 134, by way ofwhich first leg segment 124 is rotatingly connected to second legsegment 142. As best seen in FIG. 2, second leg segment 142 hascomplementary second leg segment shells 142 a and 142 b which areattached by way of a cylindrical pin 150 in second leg segment shell 142a having a bore 152 therein for receiving assembly pin 154 extendingfrom the inside surface of second leg shell 142 b. When these second legsegment shells are assembled, disk 132 of the first leg segment isseated in a corresponding circular interior space 146 with shaft 134extending through a bore in top wall 144 of second leg segment 142, thebore being formed by complementary semi-circular cut-outs 148 a and 148b in top wall 144. With disk 132 positioned in interior space 146 andresting against the interior surface 144 a of top wall 144, second legsegment 142 is capable of rotating 360° about the axis of shaft 134 atjoint 18 b with respect to first leg segment 124. Additionally, secondleg shell 142 has an arcuate opening 156 extending along the curved bodysurface of second leg segment 142 adjacent pin 150 which permitsmovement at joint 18 c, as explained below.

[0074] Left leg 18 further comprises a third leg segment 158 which actsas a double pivot member comprising. Third leg segment 158 has a plate160 with bores 162 and 164 extending transversely therethrough at theopposite ends of the plate. Third leg segment 158 is connected throughbore 162 to pin 150 second leg segment 142 to provide joint 18 c, apivot joint.

[0075] Left leg 18 further includes a fourth leg segment 166 which ispivotally connected to third leg segment 158 at joint 18 d. Fourth legsegment 166 comprises complementary fourth leg segment shells 166 a and166 b. Fourth leg segment shell 166 a is provided with a pivot pin 168which passes through bore 164 to provide pivoting motion. Pin 168 has abore 170 therein to mate with complementary assembly pin 171 in fourthleg segment shell 166 b. As will be appreciated from an inspection ofFIGS. 1 and 2, fourth leg segment 166 is analogous in structure andfunction to second leg segment 142, albeit slightly shorter in overalllength and inverted with respect to the orientation of second legsegment 142. Thus, fourth leg segment 166 has a circular interior space172 (analogous to circular interior space 146) and a bottom wall 174defining semi-circular cut outs 174 a and 174 b (shown with phantomlines) defining a bore 176 in communication with interior space 172.

[0076] Fourth leg segment 166 thus is connected to third leg segment 158by inserting pin 168 through bore 164 of the third leg segment 158 toprovide joint 18 d. Thus it will be appreciated that third leg segment158 provides a double pivot member which allows second leg segment 142and fourth leg segment 166 to independently pivot with respect to thirdleg segment 158 at joints 18 c and 18 d, respectively.

[0077] As best seen in FIG. 1, when left leg 18 is fully extendedlengthwise third leg segment 158 abuts end wall 156 a of arcuate opening156 in the bottom of second leg segment 142 and end wall 178 a definingarcuate opening 178 of the fourth leg segment to provide a continuousouter leg surface.

[0078] When second leg segment and fourth leg segment are pivoted towardeach other, each of the respective leg segments are capable of pivotingthrough an arc of about 90° (analogous to arcs C and D) such that thesecond and fourth leg segments may be pivoted a total of approximately180° with respect to one another with the third leg segment thusfunctioning as an elbow joint. Because the third leg segment 158 uses adouble pivot arrangement whereas a natural human elbow joint has asingle pivot point second and fourth leg segments are spaced apart fromeach other. To fill the gap in the outer surfaces of the second andfourth leg segments 142 and 166 where they attach to third leg segment158, third leg segment 158 is provided with wing-like extensions 180which extend outwardly and curve slight downwardly from the outer edge183 of third leg member 158 to fill in the gaps between second andfourth leg segments 142 and 166 which are needed to assure thatarticulating left leg 18 has a full range of motion about third legmember 158. The wing-like extensions thus allow leg 18 to exhibit arelatively continuous outer leg surface where second and fourth legsegments 142 and 166 are joined to third leg segment 158.

[0079] Left leg 18 further comprises a fifth leg segment 180 which isrotatingly connected to fourth leg segment 166 at joint 18 e by a disk184 spaced apart from fifth leg segment 180 by a short shaft 188. Fifthleg segment 180 has a bore 190 extending therethrough at its lower. Whenfourth and fifth leg segments 166 and 188 are rotatingly connected atjoint 18 e by inserting disk 184 into interior space 172 of fourth legsegment 166, fourth and fifth leg segments 166 and 180 are mated attheir respective walls 174 and 198 with shaft 188 extending throughbores 176 and with disk 184 seated on the interior surface of wall 174.Thus fourth and fifth leg segments 166 and 180 are capable of rotatingwith respect to one another 360° about shaft 188, with disk 184 rotatingin interior space 172.

[0080] Left foot 202 includes L-shaped left foot shells 202 a and 202 b.Left foot shell 202 a has a pivot pin 204 having a bore 206 thereinpositioned at the upper portion of the “L” and a pivot pin 208 having abore 210 therein positioned at the terminal end of the base of the L.Foot 202 further comprises large toe member 210 and smaller toe member212, which have respective proximal ends 210 a and 212 a, and bores 210b and 212 b extending transversely therethrough. Toe members 210 and 212are pivotally mounted on pivot pin 206 and fifth leg segment 180 ismounted to pivot pin 204. Left foot shell 202 b connects to foot shell202 by mating assembly pins 214 and 216 which fit in bores 206 and 210.

[0081] In another embodiment shown in FIGS. 17, 18, 26 and 27 andparticularly suitable in toy figures three inches or less in overalllength, leg 18 comprises a first leg segment 605, a second leg segment610, and an elongate member 615. First leg segment 605 has a proximalend 620 and a distal end 625, and second leg segment 610 has a proximalend 630 and a distal end 635. Elongate member 615 (see FIG. 25) has afirst end 640 and a second end 645.

[0082] Proximal end 620 of first leg segment 605 is adapted to beconnected to lower torso 252. In a preferred embodiment, shown in FIGS.17, 18 and 28, proximal end 620 is rotatably connected to hip segment660, which in turn is connected to lower torso 252. In this embodiment,proximal end 620 of first leg segment 605 comprises a disk 655 capturedby an internal space 665 formed by hip segment 660. Hip segment 660 isconnected to lower torso 252 in a manner described below.

[0083] Distal end 625 of first leg segment 605 is connected to first end640 of elongate member 615. In the embodiments shown in FIGS. 17, 26,27, 44, and 45, distal end 625 is pivotally connected to first end 640,with first end 640 comprising a ring 647 defining an aperture 650 anddistal end 625 comprising pivot pin 652 extending through aperture 650.(A perspective view of an embodiment of such an elongate member 615 isshown in FIG. 43.) In the embodiments shown in FIGS. 29, 30, 36, 46, 47and 48, distal end 625 of first leg segment 605 is rotatably connectedto first end 640, with first end 640 of elongate member 615 comprisingdisk 642 and distal end 625 defining a circular interior space 632capturing disk 642.

[0084] Proximal end 630 of second leg segment 610 is connected to secondend 645 of elongate member 615. In preferred embodiments, the second legsegment's proximal end 630 is either pivotally (see FIGS. 17, 26, 27, 2930, and 36) or rotatably (see FIGS. 43, 44, 45, 46, 47, and 48)connected to the elongate member 615 using a pivot pin or a disk,respectively, in a manner analogous to that described above with respectto distal end 625.

[0085] With further reference to FIGS. 1 and 2, trunk 12 comprises anupper torso 250 and a lower torso 252 pivotally and rotatingly connectedto one another at joint 12 a. As best seen in FIG. 1, upper torso 250has a reduced lower end 256 which is defined by a gently tapering wall258 having a collar which is partially seated in upper opening 260 inlower torso 252. Upper opening 260 thus forms a substantially circularseat to meet with the reduced end 256 of upper torso 250 such that trunk12 is capable of articulating when upper torso 250 and lower 252 areconnected by body joint 254. In a particularly preferred embodiment,upper torso is capable of pivoting left to right with respect to thelower torso over an arc of about 30° (e.g., 15° to each side) of anupright position and is capable of pivoting front to back byapproximately 30° (5° back and 25° forward) to simulate a range ofmotion about the waist of a human being. Body joint 254, which is morefully described below with reference to FIGS. 9-11, functions as a balland socket joint.

[0086] In one embodiment, the head 22 of toy FIG. 10 is substantiallyhollow and cast of a thermoplastic resin such as PVC, preferably using arotational molding technique as known in the art. The base 261 of thehead has an involuted hemispherical bottom wall 262 defining a cavity263 with a bore 264 therethrough at the top of the hemisphere. Head 22is attached to upper torso 250 by a head joint member 266 which has agenerally spherical body with an upper portion 267 supporting amushroom-shaped attachment member 270 which is sized and shaped tosnap-fit through bore 264 and be retained within the interior space ofhead 22 with the upper surface 267 of head joint 266 residing in cavity263. Joint 266 has a second attachment disk 269 (analogous to disk 30 ofjoint member 25) which is pivotally connected inside of joint member 266via lever arm 274 in an analogous manner to the slot 280 connectinglever arm 25 and first arm segment 24 as discussed below. When head 22is connected to trunk 12, head 22 is capable of pivoting about a pivotjoint located in head joint 266 (analogous to the pivot joint in firstarm segment 24) as well as rotating about disk 269. Thus, head 22 iscapable of swiveling and nodding relative to torso 250.

[0087] In another embodiment shown in FIGS. 17, 32 and 33 andparticularly suitable in toy figures three inches or less in totallength, head 22 is attached to upper torso 250 by lever arm 670. Asshown in FIGS, 31-33, lever arm 670 has a proximal end 690 and a distalend 685.

[0088] Proximal end 690 of lever arm 670 is adapted to be attached toupper torso 250. In a preferred embodiment, proximal end 690 extendsthrough slot 700 formed in the bottom of head 22 and comprises a disk695. Disk 695 is rotatably captured within slot 280 in the same manneras disk 39 described below.

[0089] Distal end 685 of lever arm 670 is located within the interior ofhead 22 and, in a preferred embodiment comprises a ring 675 defining anaperture 680. Head 22 has an internal pivot pin 705 extending throughaperture 680 to pivotally connect head 22 to lever arm 670.

[0090] Torso 250 includes slots 280 for the rotational attachment ofleft arm 14, right arm 16 and head 22. Attachment of left arm 14 willnow be described, it being understood that right arm 16 and head 22 aresimilarly attached. See FIG. 4. Left arm 14 is connected to upper torso250 at arm hole 36 by seating disk 30 within a mounting structurecomprising a slot 280 defined by vertical upstanding, parallel spacedwalls 282 and 284. Wall 284 has a semi-circular cut-out 286 along itsexposed edge and the opposite wall 282 has a horizontal upstanding ridge288 formed on its inner surface 290. Disk 30 of first arm member 24 isprovided with a groove 37 which is complementary to ridge 288 and actsas a detent when a disk 30 is rotated within slot 280. Torso shell 250 ais provided with a complementary mounting structure (not shown). Thus,when complementary upper torso shells 250 a and 250 b are matededgewise, the open ends of the complementary mounting structuresincluding particularly their respective upstanding walls abut to form aretention seat for disk 30 of first arm segment 24 with shaft 28 of armjoint 24 extending through the abutting semi-circular cut-outs 286 inthe abutting wall such that left arm member 24 and thus left arm 14 isrotatingly attached to upper torso 250. A disk attached to a shaftmember (e.g., disk 30 attached to shaft 28) and a retention seat (e.g.,slot 280 with wall 284 having a bore therethough to rotatingly seat disk30) are an example of complementary joint members or attachment meanswhich comprise a rotational joint which may be used to connect adjacentbody parts of toy FIG. 10.

[0091] Upper torso 250 and lower torso 252 are connected at joint 12 aby a body joint member 254 having a rectilinear portion 300 with a pairof laterally-extending rails 302 extending from the side walls 304 ofbody 300. Body joint member 254 further comprises a ball-member 306,rotatingly and pivotally mounted in body 300 and having a shaft 308depending therefrom and connected to a plate 310.

[0092] Portion 300 of body joint member is seated within torso 250 usinga mounting structure 281 that is different than previously described forseating disk 30 of first arm segment 24 in slot 280. Thus, mountingstructure 281 has a bottom wall 312 having a semicircular cut-out 314.Bottom wall 312 is connected to a pair of upstanding parallel spacedside walls 316, which side walls have complementary rectangular cut-outs318. Body 300 of body joint 254 is seated on bottom wall 312 withnotches 318 engaging rails 302 of the body joint and shaft 308 extendingthrough cut-out 314 and through the opening at the bottom of upper torso250. In an embodiment shown in FIGS. 17 and 34 and particularly suitablein toy figure is three inches or less in overall length, portion 300 issized so as to occupy a substantial portion of the upper torso 250.

[0093] Lower torso 252 has yet another type of mounting structure,designated by reference numeral 283, which includes an upper plate 320having a semi-circular cut-out 322 at its edge. Top plate 320 has a pairof parallel reinforcing side walls 324 to add structural support to topwall 320. Complementary top plate and reinforcing side plates are formedon lower torso shell 252 a which complementary walls abut when theshells 252 a and 252 b of lower torso 252 are mated edgewise to captureplate 310 beneath top wall 320. As will be appreciated, the length ofshaft 308 is predetermined so that when body 300 is seated on bottomwall 312 and plate 310 is seated beneath top wall 320, the reduced end256 of upper torso is pivotably and rotatably seated in substantiallycircular opening 260 of lower torso 252.

[0094] Turning to FIG. 3, assembly of action FIG. 10 proceeds withstep-wise connection of the components of the limbs and torso of actionFIG. 10 using an ultrasonic welding apparatus. The ultrasonic weldingapparatus comprises base 350 and an ultrasonic horn 352 that resonatesat a sufficiently high frequency, for example 20 kHz-40 kHz, with poweroutput of from 1000 watts to about 4000 watts to heat the surfaces ofparts which are housed within the ultrasonic welding apparatus andcauses the surfaces of the plastic parts to be welded together edgewise.As known in the art, the duration of power of the ultrasonic weldingapparatus may be controlled to assure a good weld of the intendedabutting surface.

[0095] Referring to FIGS. 3-5, in a presently preferred embodiment ofthe present invention, the ultrasonic welding assembly is carried out ina series of steps to join the limb segments into articulating limbsubassemblies and attach the limb subassemblies to one another to form acompleted limb, and then to connect the completed limbs to the upper andlower torsos 250 and 252 and the upper and lower torsos 250 and 252 toeach other.

[0096] As shown in FIG. 3, arm shell 42 a is inserted into ultrasonicbase 350 and connected to first arm segment 24 by inserting disk 32 intoreceptacle 46. Third arm segment 58 is connected to the pin 50 of armshell 42 a through the bore 62 in plate 60 and arm shell 42 b is matededgewise with complementary arm shell 42 a with assembly pin 54 beingreceived in bore 52 of pin 50. When arm shells 42 a and 42 b are mated,disk 32 (and thus first arm segment 24) is rotationally captured ininterior space 46 of second arm segment 42 and third arm segment 58 iscaptured and pivotally mounted on pivot pin 50 of second arm segment 42.Then, ultrasonic energy is applied to weld arm shells 42 a and 42 b(preferably formed of ABS) edgewise without adversely affecting theabove-described rotational and pivotal connections. The assembly soformed is a first left arm subassembly.

[0097] In the next step of assembling the left arm, arm shells 66 a and66 b of the fourth arm segment 66 are brought together for ultrasonicwelding with attaching pin 71 being received in bore 70 after connectingthe first left arm subassembly (completed in the prior ultrasonicwelding step) by connecting pin 68 through bore 64 of third arm segment58 extending from the first left arm subassembly and by inserting disk84 of lower arm joint 82 into receptacle 72. After completion of thesecond ultrasonic welding step, a second left arm subassembly isprovided which is connected, in a third ultrasonic welding, to fifthleft arm segment 80 and left hand 102. In this third ultrasonic weldingstep arm shells 80 a and 80 b are mated edgewise and welded essentiallyas described above to capture plate 86 of lower arm joint 82 inreceptacle 96 and to capture ring 104 pivotally mounted on pin 90. Afterthe third ultrasonic welding step the left arm 14 is complete.

[0098] The left leg is assembled in essentially the same manner usingthree ultrasonic welding steps as described above for assembly of theleft arm. Thus, referring to FIGS. 1 and 2, in step (1), left first legsegment 124, left leg shells 142 a and 142 b and third left leg member158 are joined in an ultrasonic welding step to provide a first legsubassembly; in step (2), a further ultrasonic welding step, the firstleg subassembly is pivotally connected by way of bore 164 in the portionof third leg member 158, extending from the first leg subassembly to pin168 of leg shell 166 a and to fifth leg segment 180 by inserting disk184 into a receptacle 172 to form a second leg subassembly; and in step(3), toe members 210 and 212 are pivotally mounted on pin 208 and pin204 is pivotally mounted through bore 190 of fifth leg segment 180 andthe foot shells 202 a and 202 b are brought together edgewise withassembly pins 214 and 216 being received in bores 206 and 210,respectively, prior to ultrasonic welding to capture second legsubassembly via bore 190 and to capture toe members 210 and 212 tocomplete left leg 18.

[0099] Right arm 16 and right leg 20 are assembled in the same manner asleft arm 14 and left leg 18.

[0100] Referring now to FIG. 4, the left arm 14 and right arm 16 areconnected to upper torso 250 by inserting disks 30 into slots 280. Thehead 22 (previously joined to head joint 266) is connected by insertingdisk 269 into slot 280. And, body 300 of body joint 254 is seated onbottom plate 312 with rails 302 received in notches 318 of side plates316. Then upper torso shells 250 a and 250 b are aligned edgewise withcomplementary slots located near the respective arm holes and opening atthe top and bottom of the torso for the head joint 266 and body joint254 abutting to capture disks 30 (arms 14 and 16) and 269 (head 22) andrails 302 (body joint 254), followed by ultrasonic welding to provide anupper torso 250 having a left arm 14, a right arm 16, a head 22 and abody joint 254.

[0101] With reference to FIG. 5, the leg assemblies and lower torso areattached to the completed upper torso (1) by seating plate 310 beneathupper wall 320 so that shaft 308 extends through semi-circular cut-out322, and (2) by positioning disks 130 in the interior space 330 definedby lower torso walls 332 and 334 with shafts 128 extending throughcutouts 332 and 334 of lower torso 252. In this orientation, thespherical outer walls 126 and 126 r of first leg segment 124 and 124 rare flush against the concave sidewalls 336 and 338 of lower torso 252.Then lower torso shells 252 a and 252 b are mated edgewise and connectedby ultrasonic welding to capture upper torso 250 and left and right legs18 and 20, thereby completing the assembly of action FIG. 10.

[0102] In another embodiment shown in FIGS. 17, 18 and 28 andparticularly suitable for use in toy figures three inches or less inoverall length, the leg and hip assemblies are attached to lower torso252 by means of shaft member 710. Shaft member 710 is captured within acavity 715 formed by lower torso 252. Shaft member 710 has a first end720 and a second end 725 projecting from lower torso 252, each endcomprising a substantially spherical ball member 730.

[0103] Hip segment 660 of each leg and hip assembly 737 comprises a pairof complimentary shells 745 and 750 defining a cavity 735 for capturingspherical ball member 730, thereby rotatably connecting hip segment 660to shaft member 710. Hip segment 660 also defines slot 740 toaccommodate the pivotal movement of shaft member 710 in relation to hipsegment 660. In the preferred embodiment, a projection 755 is situatedon shaft member 710 and is captured by cavity 715 to keep shaft member710 from rotating or moving laterally within cavity 715.

[0104] In yet another of its aspects, the present invention entails aninjection molding method for producing a joint in which a first jointmember is pivotally connected to a second joint member. This methodcomprises the steps of:

[0105] (i) inserting a first joint member having a first portion with asubstantially circular bore into an injection mold having inner wallsdefining a cavity for forming at least the second joint member, so thatthe first joint member is positioned in the injection mold so that thefirst portion is maintained in spaced relation to the walls of the moldand a second portion of the first joint member is outside of the moldcavity; and

[0106] (ii) injecting a thermoplastic composition into the cavity of themold under suitable injection molding conditions so that thethermoplastic composition fills the cavity and engulfs the first portionof the first joint member and fills the bore to form in situ a jointincluding a second joint member with a molded-in-place pivot pinpivotally connecting the first joint member to the second joint member,wherein the injecting step is carried out under injection moldingconditions that do not adversely affect the shape and structuralintegrity of the first joint member.

[0107] In another of its aspects, the present invention includes amethod for making an articulating limb having first and second limbsegments connected by an elongate member. The elongate member is formedof a first material and the first and second leg segments are formedfrom a second material having a melting point lower than the meltingpoint of the first material. In this method, the elongate member isplaced into an injection mold having a cavity for forming the first legsegment and a cavity for forming the second limb segment. The elongatemember is positioned in the injection mold such that one end of theelongate member is within the first cavity and the other end of theelongate member is within the second cavity. The second material is theninjected into the mold at a temperature equal to or higher than themelting point of the second material but lower than the first material'smelting point. In this manner, the first and second limb segments areformed around the elongate member, the first leg segment being connectedto one end of the elongate member, and the second limb segment beingconnected to the elongate member's other end.

[0108] In another of its aspects, the present invention entails aninjection molding method for making a ball and socket joint forpivotally connecting a first joint member to a second joint membercomprising the steps of:

[0109] (i) inserting a joint member having a first portion with asubstantially spherical ball member into an injection mold having innerwalls defining a cavity for forming at least the second joint member,the first joint member is positioned in the injection mold so that themajor portion of the ball member is maintained in spaced relation to thewalls of the mold and a minor portion of the ball member of the firstjoint member is outside of the mold cavity; and

[0110] (ii) injecting a thermoplastic composition into the cavity of themold under suitable injection molding conditions so that thethermoplastic composition fills the cavity and engulfs the major portionof the ball member of the first joint member to form the second jointmember including a socket pivotally connecting the first joint member tothe second joint member, wherein the injecting step is carried out underinjection molding conditions that do not adversely affect the firstjoint member.

[0111] The term “suitable injection molding conditions” meanstemperature, time and pressure conditions as known in the art whichallow a flowable thermoplastic composition to be introduced into thecavity of an injection mold so as to fill the cavity. As will beappreciated by those of ordinary skill in the art, such suitableinjection molding conditions may be routinely determined depending uponthe selected thermoplastic material. Also, by the phrase “injectionmolding conditions that do not adversely affect the first joint member,”it is meant temperature, time and pressure conditions less than thosewhich would cause either the first joint member having a boretherethrough or the first joint member comprising a ball member of aball and socket joint, to melt, distort or fuse to the second jointmember so that the first and second joint members are unable to pivotproperly with respect to each other.

[0112] In the methods of the present invention for pivotally connectinga first joint member to a second joint member, it is preferred to use avertical injection machine because of the relative ease with which aninsert part may be oriented and held in the mold during the moldingprocess. However, other injection molding apparatus, includingconventional horizontal injection molding machines, may be used withsuitably designed molds.

[0113] In the injection molding process of the invention, a first rigidjoint member is made of a first material which has a higher meltingpoint than the second joint member. The first material may be anysuitable material for an insert part including plastic, metal or thelike, so long as the first material has a melting point sufficientlyabove the melting point of the second thermoplastic material used in theclaimed process. It is presently preferred, however, that both the firstjoint member and the second joint member be made of first and secondthermoplastic materials, respectively. Also, it is preferred that thefirst joint member be injection molded.

[0114] In a particularly preferred embodiment, the first thermoplasticmaterial will have a melting temperature that is at least about 30° C.higher than the second thermoplastic material. The first thermoplasticcomposition more preferably will have a melting point which is fromabout 50° C. to about 300° C. higher than the second thermoplasticmaterial, and most preferably about 70° C. to about 140° C. higher thanthat of the second thermoplastic material. Suitable first thermoplasticmaterials may have a melting point in the range of 200° C. to 350° C.and suitable second thermoplastic compositions may have a melting pointin the range of 140° C. to 180° C. or more. Presently preferred firstthermoplastic compositions include polycarbonate having a melting pointof about 300° C., nylon having a melting point of about 300° C.,acrylonitrile-butadiene-styrene (ABS) having a melting point of about230° C., polyoxymethylene resin (POM), (e.g., POM known by the brandname Celcon), having a melting point of about 260° C., and the like.Presently preferred second thermoplastic compositions includepolyvinylchloride or Kraton (a brand name of styrene butadiene, asynthetic rubber composition) having a melting point of about 160° C. Inparticularly preferred embodiments of the invention, the first plasticcomposition is ABS and the second plastic composition is PVC.

[0115] It has been surprisingly found that where the second plasticcomposition is relatively soft compared to the first plastic compositiona sufficient coefficient of friction between the first and second jointmembers results to permit relative movement while insuring that, oncemoved, the members will remain in their new relative positions. Thisapplies as well to other pairs of joint members (including joint membersformed separately and then assembled) used to form a pivot joint or arotational joint of toy figure 10.

[0116] Referring to FIGS. 6-8, one embodiment of the molding method ofthe present invention is illustrated. FIG. 6 shows an insert piece 25′comprising ring 31 having a bore 35 transversely therethrough and a disk30′ having notches 380 cut in the circumferential edge 30 e of the disk.Ring 31 and disk 30′ are at either end of lever arm 28. Ring 35 has keys382 protruding inwardly towards the center of bore 35. Keys 382 serve toincrease pivotal friction between ring 31 and a pivot pin 33 formedtherethrough in the molding method of the present invention. Notches 380serve to prevent relative rotation between disk 30′ and disk 30 formedover disk 30′ in the molding process.

[0117] With reference to FIG. 7, first joint member 25′ (preferably madeof ABS) is placed in a vertical injection mold 388 which parts alongline 389 so that a portion of lever arm 28 and ring 31 extend into afirst cavity 390 of the mold 388 and a portion of lever arm 28 and thenotched disk portion extend into a second cavity 392 of the mold 388. Asshown in this figure, an intermediate portion of the lever arm is heldin mold 388 so that it is not in communication with either first cavity390 or second cavity 392. As will be understood by those skilled in theart, the second thermoplastic composition used to fill first cavity 390and second cavity 392 is injected under injection molding conditionsusing runner 391, which is in communication with the first cavity and asecond runner (not shown) which is in communication with the secondcavity.

[0118]FIG. 8 shows the first arm segment 24 after completion of theinjection molding process with a portion of ring 31 and disk 30′ shownin phantom lines encased in the second thermoplastic composition used inthe injection step. As best seen in FIG. 7, pivot pin 33 is formed insitu through bore 35 of ring 31.

[0119] It will be appreciated that right arm segment 24 r, left legsegment 124 and first right leg segment 124 r are formed in an analogousmanner.

[0120] An embodiment of the molding process of the present invention forproducing a ball and socket body joint 254 is illustrated in FIGS. 9-11.Body joint 254 comprises a first joint member 450 (shown in FIG. 9) anda second joint member 300 which are capable of pivoting and swivelingrelative to one another. First joint member 450 includes a ball member306 and a plate 310 spaced at either end of a shaft 308. First jointmember 450 is made of a first thermoplastic composition, preferably ABS.As shown in FIG. 10, first joint member 450 is inserted into mold 460 sothat a major portion of ball member 306 (at least greater than half ofits surface area and preferably more than 75% of its surface area) ispositioned within mold cavity 462 and a minor portion of ball member 306(less then half of its surface area) as well as shaft 308 and plate 310are positioned within mold 460 so that they are outside of communicationwith mold cavity 462. In an injection molding step, a secondthermoplastic material is injected into mold cavity 462 to establishsecond joint member 300 which has an interior surface which is formedaround the outer surface of ball 306 to establish the socket of bodyjoint 254. FIG. 11 shows the completed body joint 254 with a majorportion of ball 306 (shown in phantom lines) residing within body 300 ofbody joint 254.

[0121] An embodiment of the molding process of the present invention formaking an articulating arm having first and second arm segmentsconnected by an elongate member is illustrated in FIGS. 19, 35, 39 and42. The elongate member 510 is formed of a first material and the firstand second arm segments 500 and 505 are formed from a second materialhaving a melting point lower than the melting point of the firstmaterial. In this method, the elongate member is placed into aninjection mold 800 having a cavity 805 for forming the first arm segment500 and a cavity 810 for forming the second arm segment 505. Theelongate member 510 is positioned in the injection mold such thatelongate member's first end 535 is within the first cavity 805 and theelongate member's second end 540 is within the second cavity 810. Thesecond material is then injected into the mold 800 in the mannerdescribed above at a temperature equal to or higher than the meltingpoint of the second material but lower than the first material's meltingpoint.

[0122] In this manner, the first and second arm segments are formedaround the elongate member. In one embodiment, shown in FIG. 19, thefirst arm segment 500 forms pivot pin 550 within aperture 545 of thefirst end of the elongate member 510, and the second arm segment 505forms a pivot pin 803 within aperture 807 of the second end 540 of theelongate member 510. In another embodiment, shown in FIG. 39, first end535 of elongate member 510 comprises disk 251 and first arm segment 500forms circular interior space 560 capturing disk 251, while second end540 of elongate member 510 comprises disk 900 and second arm segment 505forms circular interior space 905 capturing disk 900. In otherembodiments, first end 535 of elongate member 510 comprises a disk andsecond end 540 of the elongate member comprises a ring defining anaperture (see FIG. 35) or vice versa (see FIG. 42).

[0123] A variation of the molding process described above, can be usedto make an articulating arm as described above and further comprising aconnecting member 565 having a body-part end 590 adapted to be connectedto the body part and a limb end 595 attached to the distal end 515 offirst arm segment 500. The connecting member 565 can be made from eitherthe same material as the elongate member 510 or a third material havinga melting point higher than the second material's melting point. In thismethod, the connecting member 565 is, like the elongate member 510,inserted into the injection mold 800 but is positioned in the injectionmold 800 so that the limb end 585 is located within the first cavity805. The second material is then injected into the first and secondcavities 805 and 810 of the mold 800 under injection molding conditionspermitting the second material to fill the first and second cavities 805and 810 and form the first arm segment 500 and the second arm segment505. The distal end 520 of the first arm segment 500 is then formedaround the first end 535 of the elongate member 510, the proximal end515 of the first arm segment 500 is formed around the limb end 595 ofthe connecting member 565, and the proximal end 525 of the second armmember 505 is formed around the second end 540 of the elongate member510. Where the connecting member 590 is made from the first material,the injecting step is carried out at a temperature lower than firstmaterial's melting point but higher than the second material's meltingpoint. Where the connecting member 590 is made from a third material,the injecting step is carried out at a temperature below the lower ofthe first and third material's melting points but higher than the secondmaterial's melting point.

[0124] Another embodiment of the molding process of the presentinvention for making an articulating leg having first and second legsegments connected by an elongate member is illustrated in FIGS. 26, 36,45 and 48. The elongate member 615 is formed of a first material and thefirst and second leg segments 605 and 610 are formed from a secondmaterial having a melting point lower than the melting point of thefirst material. In this method, the elongate member 615 is placed intoan injection mold 815 having a cavity 820 for forming the first legsegment 605 and a cavity 820 for forming the second leg segment 610. Theelongate member 615 is positioned in the injection mold 815 such thatthe elongate member's first end 640 is within the first cavity 820 andthe elongate member's second end 645 is within the second cavity 825.The second material is then injected into the mold at a temperatureequal to or higher than the melting point of the second material butlower than the first material's melting point.

[0125] In this manner, the first and second leg segments are formedaround the elongate member 615. In one embodiment, shown in FIG. 26, thefirst leg segment 605 forms a pivot pin 652 within aperture 650 of thefirst end 640 of the elongate member 615, and the second leg segment 610forms a pivot pin 830 within aperture 835 of the second end 645 of theelongate member 615. In an alternate embodiment, shown in FIG. 48, firstend 640 of elongate member 615 comprises disk 642 and first leg segment605 forms circular interior space 632 capturing disk 642 while secondend 645 of elongate member 615 comprises disk 910 and second leg segment610 forms a circular interior space 915 capturing disk 910.

[0126] In other embodiments, first end 640 of elongate member 615comprises a disk and second end 645 of elongate member 615 comprises aring defining an aperture (see FIG. 36) or vice versa (see FIG. 45).

[0127] Another aspect of the inventive molding process, a method formaking a head that is pivotally connected to a lever arm, is illustratedin FIGS. 31-33. The lever arm 670 has a distal end 685 defining anaperture 680 and the head 22 has an internal pivot pin 700 extendingthrough the aperture 680 to pivotally mount the lever arm 670 to thehead 22. The method comprises the steps of first inserting the lever arm670 into an injection mold 830 having inner walls defining a cavity 835for forming the head 22. The lever arm 670 is formed from a materialhaving a given melting point and is positioned in the injection mold sothat the distal end 685 is located within the cavity 835. Next, asufficient quantity of a first thermoplastic material is injected intothe cavity 835 mold under injection molding conditions permitting thethermoplastic material to fill the cavity 835 to form the head 22 and tofill the aperture 680 to form a pivot pin 705 extending through theaperture 680. This injecting step is carried out at a temperature thatis at least 30° C. less than the given melting point of the lever arm.

[0128] In another of its aspects, the present invention entails a methodfor making a body part having pivotable digits, such as a hand 102 of atoy figure 10 having pivotable finger members 400, 402, and 404.Referring to FIGS. 12-16, this embodiment of the invention usesinjection molding to incorporate into an articulable joint, in situ, aninsert piece comprising molded finger members 400, 402, 404. Thesefinger members are each molded of a first thermoplastic material,preferably ABS, generally in the shape of naturally-positioned, relaxedfingers. Finger members 400, 402, and 404, each of which has a proximalend 400 a, 402 a and 404 a, with a respective bore 400 b, 402 b and 404b, extending transversely therethrough for receiving a pivot pin 406 onwhich finger members 400, 402 and 404 are pivotally mounted on the pin,as shown in FIG. 14. The pivotally mounted finger members are centeredon pivot pin 136 with clearance at each end of the pin (i.e., betweenfinger member 400 and pin head 408, and between finger member 404 andpin fastener 410). As best seen in FIGS. 13 and 14, the proximal ends ofthe finger members, 400 a, 402 a and 404 a, have a combined width thatis less than the length of pivot pin 406. In this configuration havingthe combination of finger members 400, 402 and 404 pivotally attached topin 406 constitutes a first joint member (pivotally mounted on pin 136to be used) as an insert part for injection molding of left hand 102.Additionally, a second insert part for injection molding of left hand isprovided by wrist joint member 412 (preferably made of ABS) consistingof shaft 414 attached at one end to disk 416 and at the other end to aring 418. Ring 418 has a bore 420 therethrough and notches 422 toprevent relative rotation of the ring with respect to bore liner 424(made of second thermoplastic material) which is molded to the ring inan injection molding step. See also FIG. 16. Bore liner 424 increasespivotal friction achieved when hand 102 is pivotally mounted on pivotpin 90 of fourth arm segment 80 during assembly of left arm 14 to resistunintended movement of joint 14 f. See FIGS. 1 and 2.

[0129] As depicted in FIG. 16, left hand 102 is completed in a verticalinjection molding step wherein the exposed ends of pivot pin 406(including head 408 and fastener 410) and wrist joint member 412 arepositioned opposite each other in insert mold 430 having a first cavity432 sized and shaped to form the body 436 of hand 102 including a thumb438. Hand portion 436, the shape of which is defined by the shape of themold, forms around and captures pin 406 (preferably encasing pin head408 and fastener 410) to secure the fingers pivotally to hand 436 andalso forms around shaft 414 and disk 416 of wrist joint member 412.Second cavity 434 defines the surface of bore liner 424 which is formedsimultaneously with hand portion 436 to complete left hand 102 in themolding process. The injection mold 430 maintains the finger members400, 402 and 404 outside of communication with the cavity of theinjection mold so that the material used in forming hand portion 162does not fill the areas between the finger members. The molding does,however, form flush with the exposed sides 400 c and 406 c of fingermembers 400 and 406, thereby capturing the ends of pivot pin 406 alongwith pin head 408 and pin fastener 410.

[0130] Applicants' foregoing description of the present invention isillustrative. Other modifications and variations will be apparent tothose of ordinary skill in the art in light of applicants'specification, and such modifications and variations are within thescope of their invention defined by the following claims.

We claim:
 1. A toy figure having a limb with one or more joints, thelimb comprising: a first member having a proximal end comprising a diskto form a first movable joint and a distal end to form a second movablejoint; a second member having a proximal end and a distal end, theproximal end of the second member molded within the distal end of thefirst member to form the second movable joint; a third member having aproximal end and a distal end, the distal end of the third memberrotatably connected to the proximal end of the first member to form thefirst movable joint, the third member comprising a pair of shells andhaving concealed means for securing the shells together; and a fourthmember having a proximal end and a distal end, the distal end of thefourth member captured by the proximal end of the third member andconcealed means at the proximal end of the third member for capturingthe fourth member to form a third movable joint.
 2. The toy figure ofclaim 1 wherein the second movable joint formed between the first memberand second member is a pivoting joint.
 3. The toy figure of claim 1wherein the second member is of one-piece construction.
 4. The toyfigure of claim 1 wherein the first member is of one-piece construction.5. The toy figure of claim 1 wherein the first member comprises a firstmaterial having a first melting point and the second member comprises asecond material having a second melting point that is higher than thefirst melting point.
 6. The toy figure of claim 1 wherein one of thedistal end of the first member and the proximal end of the second membercomprises an aperture and the other of the distal end of the firstmember and the proximal end of the second member comprises a pin toengage the aperture.
 7. The toy figure of claim 1 wherein the proximalend of the second member molded within the distal end of the firstmember comprises an aperture and a portion of the distal end of thefirst member is molded within the aperture.
 8. The toy figure of claim 1wherein the third movable joint formed between the third member and thefourth member is a pivoting joint.
 9. A toy figure having a limb withone or more joints, the limb comprising: a first member having aproximal end and a distal end, the first member comprising two shellsand concealed means for securing the shells together; a one-piece secondmember with a proximal end and a distal end, the second member having arotational member at its proximal end; a receiving cavity at the distalend of the first member sized and shaped to receive the rotationalmember, wherein the shells of the first member capture the rotationalmember of the second member in the receiving cavity when the shells aresecured together; and a one-piece third member with a proximal end and adistal end, the proximal end of the third member including meansintegral with the third member for pivotally connecting the third memberto the distal end of the second member.
 10. The toy figure of claim 9wherein the rotational member of the second member comprises a disk. 11.The toy figure of claim 9 wherein the proximal end of the third memberis molded within the distal end of the second member.
 12. The toy figureof claim 9 further comprising a fourth member with a proximal end and adistal end, wherein the proximal end of the first member captures thedistal end of the fourth member when the shells of the first member aresecured together.
 13. The toy figure of claim 12 wherein the distal endof the fourth member is pivotally connected to the proximal end of thefirst member.
 14. The toy figure of claim 9 wherein one of the distalend of the second member and the proximal end of the third membercomprises an aperture and the other of the distal end of the secondmember and proximal end of the third member comprises a pin to engagethe aperture.
 15. The toy figure of claim 14 wherein the distal end ofthe second member comprises a pin and the proximal end of the thirdmember comprises an aperture.
 16. The toy figure of claim 12 furthercomprising a fifth member with a proximal end and a distal end, whereinthe proximal end of the fifth member is pivotally connected to thedistal end of the third member.
 17. The toy figure of claim 12 furthercomprising a fifth member with a proximal end and a distal end, whereinthe distal end of the third member is molded within the proximal end ofthe fifth member to form a movable joint.
 18. The toy figure of claim 17wherein one of the distal end of the third member and one of theproximal end of the fifth member comprises an aperture and the other ofthe distal end of the third member and the proximal end of the fifthmember comprises a pin to engage the aperture.
 19. The toy figure ofclaim 18 wherein the distal end of the third member comprises anaperture and the proximal end of the fifth member comprises a pin toengage the aperture.
 20. The toy figure of claim 17 further comprising asixth member connected to the distal end of the fifth member.
 21. Thetoy figure of claim 20 wherein the sixth member is pivotally connectedto the distal end of the fifth member.